Disassembled Views
WARNING: This page is about a different variant/trim than selected.
| Item | Part Number | Description |
|---|---|---|
| 1 | 7005 | Transmission case |
| 2 | 7A130 | Clutch support tower |
| 3 | 7D019 | Clutch support tower seals (4 required) |
| 4 | W302855 | Clutch support tower bolt (3 required) |
| 5 | 7F242 | No. 1 thrust bearing |
| 6 | 7E005 | Intermediate (2, 6) clutch piston |
| 7 | 7B070 | Intermediate (2, 6) clutch piston return spring |
| 8 | 7D483 | Intermediate (2, 6) clutch return spring snap ring |
| 9 | 7E005 | Intermediate (2, 6) clutch apply ring |
| 10 | 7C122 | Direct (3, 5, R) clutch cylinder snap ring |
| 11 | 7F283 | Direct (3, 5, R) clutch cylinder |
| 12 | 7A262 | Direct (3, 5, R) clutch piston |
| 13 | 7F235 | Direct (3, 5, R) clutch piston return spring |
| 14 | 7C099 | Direct (3, 5, R) clutch piston inner (rear) seal |
| 15 | 7C099 | Direct (3, 5, R) clutch piston inner (front) seal |
| 16 | 7A548 | Direct (3, 5, R) clutch piston outer seal |
| 17 | 7C122 | Input shaft snap ring |
| 18 | 7G384 | Direct (3, 5, R)/overdrive (4, 5, 6) clutch cylinder and hub assembly |
| 19 | 7A548 | Overdrive (4, 5, 6) clutch piston inner seal |
| 20 | 7F213 | Input shaft |
| 21 | 7D234 | No. 2 thrust bearing |
| 22 | 7B070 | Direct (3, 5, R) clutch wave spring |
| 23 | 7B164 | Direct (3, 5, R) clutch friction plates (3 required) |
| 24 | 7B442 | Direct (3, 5, R) clutch steel plates (3 required) |
| 25 | 7B066 | Direct (3, 5, R) clutch pressure plate |
| 26 | 7D483 | Direct (3, 5, R) clutch snap ring |
| 27 | 7A548 | Overdrive (4, 5, 6) clutch piston outer (rear) seal |
| 28 | 7A548 | Overdrive (4, 5, 6) clutch piston outer (front) seal |
| 29 | 7A262 | Overdrive (4, 5, 6) clutch piston |
| 30 | 7F222 | Overdrive (4, 5, 6) clutch piston return spring |
| 31 | 7H360 | Overdrive (4, 5, 6) clutch balance piston |
| 32 | 7C122 | Overdrive (4, 5, 6) clutch piston snap ring |
| 33 | 7B164 | Overdrive (4, 5, 6) clutch friction plates (5 required) |
| 34 | 7B442 | Overdrive (4, 5, 6) clutch steel plates (5 required) |
| 35 | 7B066 | Overdrive (4, 5, 6) clutch pressure plate |
| 36 | 7D483 | Overdrive (4, 5, 6) clutch snap ring |
| 37 | 7H351 | Overdrive (4, 5, 6) clutch hub |
| 38 | 7D234 | No. 3 thrust bearing |
| 39 | 7A019 | Rear planetary sun gear and shell assembly |
| 40 | 7E085 | Intermediate (2, 6) clutch wave spring |
| 41 | 7B164 | Intermediate (2, 6) clutch friction plates (2 required) |
| 42 | 7B442 | Intermediate (2, 6) clutch steel plates (2 required) |
| 43 | 7A089 | OWC |
| 44 | 7D491 | Rear planet carrier/center ring gear |
| 45 | 7C096 | No. 6 thrust bearing |
| 46 | 7G177 | No. 5 thrust bearing |
| 47 | 7B066 | Low/reverse clutch pressure plate |
| 48 | 7B164 | Low/reverse clutch friction plates (3 required) |
| 49 | 7B442 | Low/reverse clutch steel plates (3 required) |
| 50 | 7E085 | Low/reverse clutch wave spring |
| 51 | 7C122 | Low/reverse clutch piston snap ring |
| 52 | 7H318 | Low/reverse clutch piston snap ring retainer |
| 53 | 7B070 | Low/reverse clutch piston return spring |
| 54 | 7D402 | Low/reverse clutch piston |
| 55 | 7L328 | Center support |
| 56 | 7A262 | Forward (1, 2, 3, 4) clutch piston |
| 57 | 7B070 | Forward (1, 2, 3, 4) clutch piston return spring |
| 58 | 7D041 | Forward (1, 2, 3, 4) clutch piston snap ring retainer |
| 59 | 7H365 | Forward (1, 2, 3, 4) clutch piston snap ring |
| 60 | 7D491 | Center planetary carrier/front ring gear |
| 61 | 7D063 | Center planetary sun gear |
| 62 | 7C096 | No. 7 thrust bearing |
| 63 | 7C096 | No. 8 thrust bearing |
| 64 | 7D491 | Front planetary carrier/rear ring gear |
| 65 | 7A019 | Front planetary sun gear and shell assembly |
| 66 | 7D234 | No. 10 thrust bearing |
| 67 | 7B070 | Forward (1, 2, 3, 4) clutch wave spring |
| 68 | 7B164 | Forward (1, 2, 3, 4) clutch friction plates (2 required) |
| 69 | 7B442 | Forward (1, 2, 3, 4) clutch steel plates (2 required) |
| 70 | 7B066 | Forward (1, 2, 3, 4) clutch pressure plate |
| 71 | 7D483 | Forward (1, 2, 3, 4) clutch snap ring |
| 72 | 7978 | Transmission fluid baffle |
| 73 | W500214 | Transmission fluid baffle bolt (2 required) |
| 74 | 7060 | Park gear |
| 75 | 7G132 | Drive chain drive sprocket |
| 76 | 7C122 | Drive sprocket snap ring |
| 77 | 7G099 | No. 13 thrust washer |
| 78 | 7G249 | Drive chain |
| 79 | 7D234 | No. 11 thrust washer |
| 80 | 7048 | Input shaft seal |
| 81 | 7A098 | Transmission fluid filter |
| 82 | 7L027 | Magnet |
| 83 | W302860 | Pump-to-torque converter housing bolt (8 required) |
| 84 | 7A103 | Pump assembly |
| 85 | 7A248 | Pump assembly-to-torque converter housing O-ring seal |
| 86 | 7A248 | Torque converter hub seal |
| 87 | 7P113 | Torque converter hub seal retainer |
| 88 | 7F343 | Different ring gear |
| 89 | 7C122 | Differential ring gear snap ring |
| 90 | 7H245 | Differential transmission fluid baffle |
| 91 | W500214 | Differential transmission fluid baffle bolt (2 required) |
| 92 | 7975 | Torque converter housing |
| 93 | W701606 | Torque converter housing stud bolt |
| 94 | 7A443 | Torque converter housing bolt (16 required) |
| 95 | 7902 | Torque converter |
| 96 | 1177 | RH halfshaft seal |
| 97 | 7G355 | No. 12 thrust bearing |
| 98 | 7G132 | Drive chain driven sprocket |
| 99 | 7F342 | Differential sun gear |
| 100 | 7F465 | Differential assembly |
| 101 | 7G112 | No. 15 thrust bearing |
| 102 | 7B362 | Torque converter housing-to-transmission case guide pins |
| 103 | 7D070 | Park pawl spring |
| 104 | 7A441 | Park pawl |
| 105 | 7D071 | Park pawl pin |
| 106 | 7F337 | Manual control shaft seal |
| 107 | 7A232 | Park pawl actuator rod |
| 108 | 7H557 | TR sensor |
| 109 | 7C493 | Manual control shaft |
| 110 | 7G100 | Manual control shaft pin |
| 111 | 7A256 | Manual control lever |
| 112 | W708455 | Manual control lever nut |
| 113 | 7E332 | Manual valve detent spring |
| 114 | W711235 | TR sensor detent spring bolt |
| 115 | 7J387 | Fluid reservoir |
| 116 | 7A248 | Clutch feed seal (large) |
| 117 | 7A248 | Clutch feed seal (small) (4 required) |
| 118 | 7B431 | Main control alignment pin |
| 119 | 7C207 | Main control stud |
| 120 | 7G199 | Main control-to-transmission case seal (2 required) |
| 121 | W713644 | OSS sensor bolt |
| 122 | 7H103 | OSS sensor |
| 123 | 7Z490 | Main control-to-transmission case separator plate |
| 124 | 7A100 | Main control valve body |
| 125 | N605770 | Separator plate-to-solenoid body bolt (2 required) |
| 126 | 7Z490 | Main control valve body-to-solenoid body separator plate |
| 127 | 7G391 | Solenoid body |
| 128 | W500303 | Solenoid body-to-valve body bolt (2 required) |
| 129 | W302863 | Main control-to-transmission case bolt (long) (10 required) |
| 130 | W302862 | Main control-to-transmission case bolt (short) (12 required) |
| 131 | W520412 | Main control nut |
| 132 | 7G276 | Main control leadframe |
| 133 | W505513 | Main control leadframe screw (5 required) |
| 134 | 7B329 | Main control-to-cover seal |
| 135 | 7G004 | Main control cover |
| 136 | W714629 | Main control cover stud bolt (5 required) |
| 137 | W500214 | Main control cover bolt (8 required) |
| 138 | 7010 | Drain plug |
| 139 | 7H398 | Line pressure tap |
| 140 | - | Oil leveling plug |
| 141 | 1177 | LH halfshaft seal |
| 142 | 7025 | LH halfshaft bushing |
| 143 | 7M101 | TSS sensor |
| 144 | W500214 | TSS bolt |
| 145 | 7A246 | Vent tube |
| 146 | W500214 | Fluid reservoir bolts |
| 147 | 7G342 | Solenoid body strategy tag |
| 148 | 7B148 | Transmission service identification tag |
| 149 | - | Direct clutch (3, 5, R) |
| 150 | - | Intermediate clutch (2, 6) |
| 151 | - | Overdrive clutch (4, 5, 6) |
| 152 | - | Forward clutch (1, 2, 3, 4) |
| 153 | - | Low/reverse clutch |
- Special Tool(s): Holding Fixture 307-625.
- Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B), Holding Fixture 307-625.
General Equipment: Work Bench.
- Special Tool(s): Retainer, Torque Converter 307-566.
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NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Special Tool(s): Handle, Torque Converter 307-091 (T81P-7902-C).
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NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission and torque converter being serviced.
Visual check.
- Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
- A new or remanufactured torque converter must be installed if one or more of the following statements is true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes.
- Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
- If none of the above conditions are present, continue with the following fluid inspection.
- Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
- Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
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NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur.
Drain the remaining fluid from the torque converter. Apply the specified amount of fluid.
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NOTE: Note the location of the stud bolts for assembly.
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NOTE: Note the location of the short and long main control-to-transmission case bolts for reassembly.
- Clean and inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it. Refer to MAIN CONTROL - OVERHAUL .
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NOTE: Note the location of the stud bolts for assembly.
- General Equipment: Pry Bar.
- Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear. Install new components, if necessary. Refer to DIFFERENTIAL GEAR ASSEMBLY .
- Check for damage or excessive wear.
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NOTE: Simultaneously lift the drive, driven sprockets and chain.
- Check for damage or excessive wear.
- Check that bearing spins freely. Check for damage or excessive wear.
- Check for damage or excessive wear.
- Check for damage or excessive wear.
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NOTE: Note the location of the snap ring gap for assembly.
- Clutch pressure plate, clutch plates and wave spring.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Check for damage or excessive wear.
- Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
- Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
- Check for damage or excessive wear.
- Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear.
- Wave spring, clutch plates and pressure plate.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
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NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.NOTE: The low OWC should not be disassembled.
Check for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise.
- Check for burned or excessively worn surface.
- Inspect the clutch plate surfaces for damage or excessive wear.
- Check for damage or excessive wear.
- Pressure plate and the wave spring.
- Inspect the pressure plate surface for damage or excessive wear.
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NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
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NOTE: Note the location of the snap ring gap for assembly.
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NOTE: Note the position of the return spring for assembly.
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NOTE: Note the position of the intermediate clutch piston for assembly.
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NOTE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transmission case causing damage to the transmission case.
Special Tool(s): Remover, Roll Pin 211-061 (T78P-3504-N1).
- General Equipment: Pry Bar.
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NOTE: If the LH transmission case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transmission case bushing and a new LH halfshaft must be installed, or excessive noise or transmission failure can occur.
If the LH transmission case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components. Refer to TRANSMISSION CASE .
- General Equipment: Pry bar.
- If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear. Refer to TRANSMISSION CASE .
- Special Tool(s): Slide Hammer 100-001 (T50T-100-A), Actuator Pin 303-D011 (D80L-100-G), Collet, 3/4 Inch to 7/8 Inch 303-D019 (D810L-100-Q).
- General Equipment: Dent puller.
- Bolts hand-tight.
- Compress the valve spring with a screwdriver and remove the retainer with a magnet.
General Equipment: Screwdriver, Magnet.
- General Equipment: M4 bolt.
- Compress the valve spring with a screwdriver and remove the retainer with a magnet.
General Equipment: Screwdriver, Magnet.
- Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump assembly for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the pump assembly as an assembly.
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NOTE: TCC control valve retainer shown in illustration assembled in the pump body, main pressure regulator valve retainer similar.
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NOTE: The dot on the inner pump gear faces up.
- Bolts hand-tight.
- Bolts hand-tight.
- Special Tool(s): Installer, Converter Seal 307-627.
- Special Tool(s): Installer, Converter Seal 307-627.
- Special Tool(s): Seal Installer, Turbine Shaft 307-634.
- Special Tool(s): Seal Installer, Turbine Shaft 307-634.
- New O-ring.
Material: Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
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NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.
Position the center support on a press with the long legs facing up.
Special Tool(s): Compressor, Center Support Piston Spring 307-630.
General Equipment: Shop Press.
- Apply 483 kPa (70 psi) of air pressure.
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NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Position the center support on a press with the short legs facing up.
Special Tool(s): Compressor, Center Support Piston Spring 307-630.
General Equipment: Shop Press.
- Apply 483 kPa (70 psi) of air pressure.
- Check for damage or excessive wear.
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NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Short leg side of the center support facing up.
Special Tool(s): Seal Protector, Low Reverse Piston 307-628/2, Seal Protector, Low Reverse / 1-2-3-4 Piston 307-629.
- Shop Supplies: Petroleum Jelly.
- Special Tool(s): Seal Protector, Low Reverse Piston 307-628/2, Seal Protector, Low Reverse / 1-2-3-4 Piston 307-629.
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NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
- Position the center support on a press with the short legs facing up.
Special Tool(s): Compressor, Center Support Piston Spring 307-630.
General Equipment: Shop Press.
- Check the snap ring to be sure it is seated in the groove.
- Position the center support with the long legs facing up.
Special Tool(s): Seal Protector, Low Reverse Piston 307-628 (includes 307-628/1 and 307-628/2).
- Shop Supplies: Petroleum Jelly.
- Special Tool(s): Seal Protector, Low Reverse Piston 307-628 (includes 307-628/1 and 307-628/2).
- Position the center support on a press with the long legs facing up.
Special Tool(s): Compressor, Center Support Piston Spring 307-630.
General Equipment: Shop Press.
- Check the snap ring to be sure it is seated in the groove.
- Check for damage or excessive wear.
- Align the bottom edge of the tool with the top edge of the bottom Teflon seal groove.
Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
- Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
- Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/2, Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
- Remove tools and repeat steps for the other 3 Teflon seals.
Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/2, Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/3.
- Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/1.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring 307-584/2.
- Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring 307-584/2.
General Equipment: Shop Press.
- Remove the special tool.
Special Tool(s): Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578/1.
- Apply compressed air to the piston port.
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NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/2, Compressor, Forward/Intermediate Spring 307-584/2.
General Equipment: Shop Press.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Check for damage or excessive wear.
- Shop Supplies: Petroleum Jelly.
- Soak the clutch plates.
Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
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NOTE: Install the return spring with the flat side facing down.
- Shop Supplies: Petroleum Jelly.
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NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/2, Compressor, Forward/Intermediate Spring 307-584/2.
General Equipment: Shop Press.
- Shop Supplies: Petroleum Jelly.
- Shop Supplies: Petroleum Jelly.
- Install by hand.
Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1.
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NOTE: Holes face up on the clutch piston return spring.
- Shop Supplies: Petroleum Jelly.
- Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring Compressor 307-584/2.
- Special Tool(s): Compressor, Overdrive Clutch, Balance Piston and Direct Clutch 307-589/1, Compressor, Forward/Intermediate Spring Compressor 307-584/2.
General Equipment: Shop Press.
- Soak the clutch plates.
Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
- Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Position the plunger on the overdrive (4, 5, 6) clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.
Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
- Mallet.
Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
- Special Tool(s): Manual Lever Seal Installer 307-581.
- Special Tool(s): Manual Lever Seal Installer 307-581.
- Special Tool(s): Seal Protector, 2-6 Piston 307-632.
- Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
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NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transmission can occur.
- Position the clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transmission case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
- Push the clutch piston into the clutch cylinder by hand.
Special Tool(s): Compressor, Forward/Intermediate Spring 307-584/1.
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NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transmission can occur.
The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
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NOTE: Be sure the snap ring is aligned with the gap facing the front of the transmission or damage to the transmission can occur. The front of the transmission is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
Align the gap of the snap ring to face the front of the transmission.
- Special Tool(s): Spring Compressor, 2-6 Piston Return 307-633/2.
- Special Tool(s): Spring Compressor, 2-6 Piston Return 307-633/1.
- Special Tool(s): Compressor, Forward Clutch Spring 307-574/1.
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NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transmission case.
Special Tool(s): Compressor, Forward Clutch Spring 307-574/1, Spring Compressor, 2-6 Piston Return 307-633 (Includes 307-633/1 and 307-633/2).
General Equipment: Wrench.
- Tap the ring in place.
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NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transmission can occur.
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NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transmission can occur.
- Clutch wave spring.
- Soak the clutch plates.
Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
- Position the clutch plates, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
- Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
- Record as measurement A, the distance from the Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the clutch plate at 3 different points and average the 3 distances.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Record as measurement B, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the transmission case step above the intermediate (2, 6) clutch. Measure the length or distance.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in) -
NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
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NOTE: Note the position of the pressure plate. When installing the center support, the long support legs must fit through the pressure plate and rest on the OWC .
- Soak the clutch plates.
Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
- Position the wave spring and clutch plate, temporarily reversing the wave spring and steel plate for the clutch stack-up measurement.
- Position the center support with the long legs facing up.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
- Record as measurement A, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the contact surface of the low/reverse clutch piston.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Record as measurement B, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the leg surface of the center support.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Subtract measurement B from measurement A and record as measurement C.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and record as measurement C. - Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
- Record as measurement D, the distance from the Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the OWC
.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Record as measurement E, the distance from the top of Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055) to the top of the low/reverse clutch at 3 different points and average the 3 distances.
Special Tool(s): Shim Selection Gauge 307-300 (T94P-77000-Q) (17-055).
General Equipment: Depth Gauge.
- Subtract measurement E from measurement D and record as measurement F.
Description Reading Measurement D Measurement E Subtract measurement E from measurement D and record as measurement F - Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
Description Reading Measurement C Measurement F Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in) -
NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
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NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transmission.
- Wave spring.
- Soak the clutch plates.
Material: Clean Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC.
- Clutch plates.
- Pressure plate.
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NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transmission.
Clutch beveled snap ring with the flat side down with the gap facing the front of the transmission.
- Seat the snap ring in the snap ring groove.
- Position the plunger on the top clutch friction plate.
Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Apply 483 kPa (70 psi) of air pressure to the clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.076 mm (0.002 in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transmission for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
Special Tool(s): Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C).
- Align the manual control shaft pin holes.
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NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
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NOTE: Simultaneously lower the drive, driven sprockets and chain.
Lightly tap on the driven sprocket to be sure it is fully seated in the case.
- Special Tool(s): Seal Protector, Turbine Shaft 307-635.
- FWD
Vehicles.
Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
- FWD
Vehicles.
Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Differential Seal 307-626.
- AWD
Vehicles.
Special Tool(s): Installer, RH Halfshaft Fluid Seal 307-428.
- AWD
Vehicles.
Special Tool(s): Installer, RH Halfshaft Fluid Seal 307-428.
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NOTE: Be sure the sealing surfaces of the torque converter housing and the transmission housing are free of oil before applying silicone.
Material: Ultra Silicone Sealant TA-29.
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NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
- Remove the special tool.
Special Tool(s): Seal Protector, Turbine Shaft 307-635.
- Align the new separator plate on the stud and the guide pin.
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NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
- Nut hand-tight.
- Short bolts hand-tight.
- Long bolts hand-tight.
- Tighten in a crisscross pattern.
- Alignment tab in the alignment hole.
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NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
- Material: Ultra Silicone Sealant TA-29.
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NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
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NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Special Tool(s): Handle, Torque Converter 307-091 (T81P-7902-C).
- Special Tool(s): Retainer, Torque Converter 307-566.
- Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B), Holding Fixture 307-625.
- Special Tool(s): Holding Fixture 307-625.